Patent EA-003152-B1 (EA)
Title: Method for manufacturing a binder and use thereof
Inventor: PERANDER MICHAEL
IPC: D04H1/587
Filed: 2000-06-20
Abstract: 1. Method for making a binder comprising the steps of -dissolving a particulate mineral material having a glassy amorphous structure in an aqueous solution, to form a solution containing nucleated re-precipitated particles from the material, -stabilizing the so obtained solution to form a sol having the desired particle size, and optionally -adjusting the dry matter content of the sol. 2. The method according to claim 1, wherein the particulate mineral material is a mineral wool material from mineral fibre production, such as spinning waste, unused fibres or products, as well as post-consumer mineral fibre products. 3. The method according to any preceding claim, wherein the solution is stabilized by means of a pH change or by changing the electrolytic character of the solution. 4. The method according to any preceding claim, wherein the solution is stabilized by means of surfactants and/or polymers. 5. The method according to any of the preceding claims, wherein the aqueous solution is an alkaline solution. 6. The method according to claim 5, wherein the alkaline solution is an alkali or ammonium, or an alkaline earth metal hydroxide, carbonate or hydrocarbonate solution, preferably selected from the group consisting of a sodium, potassium, lithium or ammonium, or calcium or magnesium hydroxide solution. 7. The method according to 5 or 6, wherein the alkaline solution is a 0.1-2 molar alkaline solution. 8. The method according to any one of the claims 1 to 4, wherein the aqueous solution is acidic, being a solution of an inorganic or organic acid, preferably an aqueous solution containing an acid selected from HCl, HNO3, H2SO4, H3PO4, formic, acetic and propionic acid. 9. The method acording to any one of the preceding claims, wherein the stabilized sol has a dry matter content of 5 to 60 % by weight. 10. The method according to any one of the preceding claims, wherein the particle size of the sol is appr. 1 to 1000 nm, preferably 10 to 100 nm. 11. The method according to any one of the preceding claims, wherein the dissolution takes place at a temperature of 80 to 100 C, preferably while stirring. 12. The method according to claim 1, wherein the sol obtained is made to form a gel prior to contacting the same with the material to be bonded. 13. The method according to claim 12, wherein the gel formation is brought about by affecting a pH change and/or by the addition of a salt. 14. The method according to any one of the preceding claims, comprising an additional step of contacting the binder with a particulate mineral material, for the purpose of manufacturing a mineral wool product, or a raw material briquette for mineral wool production, or an iron ore briquette. 15. Method for the production of a mineral wool product comprising the steps of -dissolving a particulate mineral material having a glassy amorphous structure in an aqueous solution, to form a solution containing nucleated re-precipitated particles from the material, -stabilizing the so obtained solution to form a sol having the desired particle size to form a binder solution, and optionally -adjusting the dry matter content of the binder solution, and -contacting the so obtained binder with mineral wool fibres to bind the same. 16. The method according to claim 15, wherein the sol obtained is made to form a gel prior to contacting the same with the mineral wool fibres. 17. The method according to claim 16, wherein the gel formation is brought about by affecting a pH change and/or by the addition of a salt. 18. The method according to claim 15, wherein the binder is contacted with the fibres immediately after fibre formation. 19. The method according to claim 15, wherein the binder is applied to a mineral wool web made from the fibres.